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ABB 1KHL178025R0102P (COM02) Circuit Board 

1. Key Parameters

• Product Model: COM02
• Order Code: 1KHL178025R0102P
• Product Series: ABB COM Series Industrial Communication Circuit Boards (Protocol Conversion, Automation System Interfacing)
• Core Function: Enables protocol conversion between ABB automation systems and field devices; processes and buffers industrial data; conditions communication signals; supports remote I/O network integration; ensures reliable cross-system data transmission
• Electrical & Communication Specifications:

  Parameter	Details	Performance Metrics
  Supported Protocols	- Primary Protocols: PROFIBUS DP V1, Modbus RTU/TCP - Secondary Protocols: Ethernet/IP (optional, via firmware update) - Protocol Conversion Latency: ≤10ms (between PROFIBUS and Modbus) - Data Rate: PROFIBUS DP (up to 12Mbps); Modbus TCP (up to 100Mbps, 10/100Base-T)	Enables seamless integration with 90% of industrial field devices (e.g., sensors, drives) and external control systems
  Signal Interface	- Physical Interfaces: 1×PROFIBUS DP (RS-485); 1×Modbus RTU (RS-485); 1×Ethernet (RJ45, 10/100Base-T) - Signal Isolation: 2.5kV AC (RS-485 interfaces, 1min); 1kV AC (Ethernet interface, 1min) - Common-Mode Rejection: ≥80dB (at 50/60Hz, RS-485) - Cable Distance: Up to 1200m (PROFIBUS DP, 9.6kbps); up to 100m (Ethernet)	Prevents noise interference and ground loops in long-distance communication, ensuring signal integrity in large facilities
  Data Processing	- Maximum Data Buffer: 8kB (inbound/outbound) - Concurrent Connections: Up to 8 Modbus TCP clients; 1 PROFIBUS DP master/slave - Error Detection: CRC-16 (Modbus); HDLC framing (PROFIBUS) - Data Update Rate: 100ms (configurable, minimum 10ms)	Handles high-volume industrial data without packet loss, supporting real-time control requirements (e.g., 100ms update for process variables)
  Safety & Protection	- Overvoltage Protection: ±15kV ESD (contact, IEC 61000-4-2) - Short-Circuit Protection: Current limiting (RS-485 drivers, auto-recovery) - Power Protection: Reverse polarity protection (24V DC input) - Flame Class: UL 94 V0 (board substrate)	Protects the circuit board from electrical anomalies (e.g., static discharge during maintenance, shorted communication cables)

• Mechanical Specifications:
  • Dimensions: 60mm (W) × 100mm (L) × 25mm (H) (board-level design for rack mounting)
  • Mounting Type: ABB standard I/O rack slot (compatible with S800 racks); DIN rail mount (via optional adapter)
  • Housing Material: FR-4 glass-epoxy substrate (flame-retardant); conformal coating (IPC-A-610 Class 3, moisture/dust resistance)
  • Weight: Approximately 80g
  • Power Requirements: 24V DC ±10% (19.2V~26.4V DC); 1.2W (typical), 2W (max load)
• Environmental Ratings:
  • Operating Temperature Range: -20℃~+65℃ (-4℉~149℉)
  • Storage Temperature Range: -40℃~+85℃ (-40℉~185℉)
  • Humidity Tolerance: 5%~95% RH (non-condensing, 40℃)
  • Altitude Rating: Up to 2000m (no derating required)
  • Vibration Resistance: 10~500Hz, 1.5g acceleration (IEC 60068-2-6; no solder joint failure)
  • Shock Resistance: 30g (11ms half-sine, IEC 60068-2-27; no component damage)
• Compliance Standards: CE, RoHS, IEC 61131-2 (industrial controllers), EN 61000-6-2 (EMI immunity), ABB Automation System Compatibility Standard (800xA V6.0+, AC800M V5.1+)

2. Key Features

• Multi-Protocol Support: Natively supports PROFIBUS DP, Modbus RTU/TCP, and optional Ethernet/IP—eliminates the need for multiple communication modules, reducing cabinet space and integration complexity (e.g., connecting a PROFIBUS-based drive to a Modbus TCP PLC).
• Low-Latency Protocol Conversion: ≤10ms latency between protocols—ensures real-time data transmission for time-sensitive applications (e.g., process control loops, motor speed adjustment), avoiding delays that cause process instability.
• High-Level Signal Isolation: 2.5kV AC isolation for RS-485 interfaces and 1kV AC for Ethernet—prevents ground loops (a major cause of communication failures in distributed systems) and protects the board from voltage spikes in distant field networks.
• Conformal Coating Protection: IPC-A-610 Class 3 conformal coating—resists moisture, dust, and industrial contaminants (e.g., oil, chemicals), making it suitable for harsh environments: food processing washdowns, mining dust, and offshore humidity.
• Compact Board-Level Design: 60mm×100mm form factor fits standard ABB S800 I/O rack slots—saves 50% space compared to standalone communication gateways, enabling dense installation alongside I/O modules (e.g., DI825, AI893) and termination units (e.g., TU860).
• Flexible Configuration: ABB Communication Configurator software simplifies protocol setup, data mapping, and error logging—enables non-specialized technicians to configure the board in <30 minutes, accelerating commissioning.
• Robust Error Handling: CRC-16 error detection, data buffering, and auto-recovery for short circuits—minimizes data loss during transient communication issues (e.g., cable interference), ensuring 99.99% communication availability.

3. Application Fields

• ABB Automation System Communication: Primary application—bridging ABB controllers and field devices:
  • Chemical Plant 800xA DCS Integration: Converts PROFIBUS DP signals from ABB ACS800 drives to Modbus TCP for 800xA DCS monitoring; ≤10ms latency ensures real-time drive speed adjustment (e.g., for reactor agitators), maintaining process temperature stability.
  • AC800M PLC Remote I/O Linking: Connects Modbus RTU-based remote I/O modules (e.g., temperature sensors in a refinery) to AC800M PLCs via Ethernet/IP; 2.5kV isolation prevents ground loops between the PLC cabinet and remote field enclosures.
• Industrial Protocol Conversion: Enabling cross-system communication:
  • Automotive Factory Robot Networks: Converts PROFIBUS DP signals from robotic controllers to Modbus TCP for MES (Manufacturing Execution System) data collection; data buffering (8kB) handles peak data loads during high-volume production shifts, avoiding packet loss.
  • Water Treatment Plant SCADA Integration: Links Modbus RTU-based flow meters and level sensors to a SCADA system via Ethernet/IP; conformal coating resists moisture in pump station enclosures, ensuring reliable data transmission for water distribution monitoring.
• Harsh Environment Communication: Reliable data transfer in extreme conditions:
  • Mining Underground Control Systems: Connects PROFIBUS DP-based gas detectors and conveyor controls to surface PLCs; wide temperature range (-20℃~+65℃) handles cold underground environments, while ESD protection (±15kV) withstands static discharge from mining equipment.
  • Food Processing Line Data Sharing: Converts Modbus RTU signals from washdown-compatible sensors to Ethernet/IP for 800xA DCS; conformal coating resists caustic cleaners during weekly washdowns, complying with FDA hygienic standards.
• Infrastructure & Energy Sector Communication: Supporting critical monitoring:
  • Solar Farm Inverter Data Collection: Links Modbus TCP-based inverters to a central SCADA system via Ethernet/IP; high vibration resistance (1.5g) withstands wind-induced motion in outdoor inverter enclosures, ensuring continuous energy production monitoring.
  • Railway Signaling Interfaces: Converts PROFIBUS DP signals from trackside sensors to Modbus RTU for train control systems; shock resistance (30g) withstands train-induced impacts, maintaining safe signaling operation.

4. Precautions

• Protocol Compatibility (Critical): Verify that the board’s supported protocols match the target system (e.g., PROFIBUS DP for ABB drives, Modbus TCP for SCADA)—using an unsupported protocol requires a firmware update (via ABB’s official portal); unauthorized firmware modifications void the warranty.
• Installation & Wiring Safety:
  • Interface Isolation: Maintain 2.5kV creepage/clearance distances (≥6mm) for RS-485 wiring and 1kV distances (≥3mm) for Ethernet—reduced distances compromise isolation, leading to communication failures or board damage.
  • Polarity & Wiring: Follow correct polarity for 24V DC power input (reverse polarity protection prevents damage but interrupts operation); use twisted-pair shielded cable (24 AWG) for RS-485/Ethernet to reduce noise—unshielded cables increase EMI susceptibility.
  • Grounding: Connect the board’s signal ground to the system’s communication ground (not power ground)—shared grounding causes noise coupling, degrading signal quality (e.g., Modbus CRC errors).
• Operation & Maintenance:
  • Configuration Backup: Save the board’s configuration (via ABB Communication Configurator) after setup—restoring from backup reduces downtime if the board requires replacement; store backups in a secure, version-controlled system.
  • 定期检查: Inspect quarterly for:
    • Loose connector pins (common after vibration events)
    • Conformal coating damage (from mechanical impact or harsh chemicals)
    • Communication error logs (via 800xA or Configurator software)
      Clean dust from connectors with a dry brush—avoid liquid cleaners (damage the coating).
  • Firmware Updates: Only install official ABB firmware updates (available via ABB Industrial Portal)—outdated firmware may have security vulnerabilities or protocol compatibility issues; update during planned maintenance to avoid disrupting operations.
• Environmental Limitations:
  • Temperature Extremes: Do not operate above +65℃ or below -20℃—high temperatures degrade component performance (e.g., increased latency), while extreme cold causes solder joint brittleness; use cabinet heaters/coolers in extreme zones.
  • Condensing Humidity: Avoid operation in condensing humidity (>95% RH, 40℃)—condensation penetrates conformal coating over time, causing short circuits; use dehumidifiers in humid environments (e.g., offshore platforms, water treatment plants).
• Replacement & Spare Parts:
  • Genuine ABB Components: Use only genuine ABB 1KHL178025R0102P (COM02) boards—non-genuine alternatives lack isolation standards and protocol validation, leading to communication failures and potential damage to connected ABB controllers.
  • Spare Inventory: Maintain 1 spare board per 5 operational units—communication failures disconnect critical data flows (e.g., drive control, sensor monitoring); spares reduce downtime from 1+ week (delivery) to <1 hour for mission-critical systems

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